Leakage current detection interrupter

ABSTRACT

An LCDI device includes a shell, a movement unit, and a wire bundle assembly. The shell includes a base and an upper cover connected to each other. The movement unit is disposed in the base, and includes at least one connecting conductor. A first end of the wire bundle assembly is disposed in the upper cover and includes at least one shield detection line, where the shield detection line is electrically coupled to the connecting conductor. The shield detection line includes a connecting terminal at the first end of the wire bundle assembly which is configured to received and retain the connecting conductor inserted therein. The structure of the LCDI enables fast and secure assembling of the wire bundle assembly and movement unit, and eliminates the need for internal re-adjustment of the shield detection lines after assembling, which promotes automation of large scale production.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to electrical circuit protection, and inparticular, it relates to a leakage current detection interrupter (LCDI)device.

Description of Related Art

With the wide use of home electrical appliances, safety becomes more andmore important. Currently, many home appliances are equipped withelectrical circuit protection devices, such as leakage current detectioninterrupters (LCDI). An LCDI device uses a detection line in the powercord, such as a shield detection line, to detect a leakage current thatexceeds a predetermined threshold. Such leakage current can occur whenthe hot or neutral wire of the power cord is aged, worn, damaged byanimal crewing, etc. causing the insulation of the wires to be damagedand lose insulation effectiveness. Upon detecting a leakage current, theLCDI device will cut off the electrical connection between the input endand the output end to ensure safety and prevent fire hazard.

Assembling a conventional LCDI device requires putting multipleindividual parts together, and requires utilizing tools to assist infixing the positions of some of the parts in order to complete theassembly. This assembly process is time consuming and inefficient.

SUMMARY

To solve the above problems, embodiments of the present inventionprovide an LCDI device, which includes a shell, a movement unit, and awire bundle assembly. The shell includes a base and an upper coverconnected to each other. The movement unit is disposed in the base, andincludes at least one connecting conductor. A first end of the wirebundle assembly is disposed in the upper cover and includes at least oneshield detection line, where the shield detection line is electricallycoupled to the connecting conductor. The shield detection line includesa connecting terminal at the first end of the wire bundle assembly whichis configured to received and retain the connecting conductor insertedtherein.

In some embodiments, the connecting conductor includes a conductor platedefining a positioning hole, and a position limiting structure disposedon one side of the conductor plate.

In some embodiments, the connecting terminal includes a bump on an innerside, wherein the bump is configured to fall into the positioning holeof the conductor plate when the conductor plate is inserted into theconnecting terminal, and wherein the position limiting structure isconfigured to limit a longitudinal position of the conductor plateinserted into the connecting terminal, whereby the conductor plate andis electrically coupled to the shield detection line.

In another aspect, the present invention provides an LCDI device, whichincludes: a shell, including a base and an upper cover connected to eachother; a movement unit disposed in the base; and a wire bundle assembly;wherein the movement unit includes at least one first fastener memberlocated on a first sidewall of the movement unit, and at least onesecond fastener member located on a second sidewall of the movement unitopposite the first sidewall; wherein the base has at least one firstfastener member corresponding to the at least one first fastener memberof the movement unit, and at least one second fastener membercorresponding to the at least one second fastener member of the movementunit; and wherein each first fastener member of the movement unit isconfigured to cooperate with a corresponding first fastener member ofthe base, and each second fastener member of the movement unit isconfigured to cooperate with a corresponding second fastener member ofthe base, to assemble the movement unit in the base.

In another aspect, the present invention provides an LCDI device, whichincludes a shell, including a base and an upper cover connected to eachother; a movement unit disposed in the base; and a wire bundle assembly;wherein the upper cover includes at least one third fastener memberlocated on a first sidewall of the upper cover, and at least one fourthfastener member located on a second sidewall of the upper cover oppositethe first sidewall; wherein the base has at least one third fastenermember corresponding to the at least one third fastener member of theupper cover, and at least one fourth fastener member corresponding tothe at least one fourth fastener member of the upper cover; and whereineach third fastener member of the upper cover is configured to cooperatewith a corresponding third fastener member of the base, and each fourthfastener member of the upper cover is configured to cooperate with acorresponding fourth fastener member of the base, to assemble the uppercover to the base.

In some embodiments, the shell further includes a rear cover configuredto be connected to a part of the upper cover, wherein the first end ofthe wire bundle assembly is disposed between the rear cover and theupper cover.

In another aspect, the present invention provides an LCDI device, whichincludes a shell, including a base and an upper cover connected to eachother; a movement unit disposed in the base, having at least one inputcontact terminal and at least one corresponding output contact terminal;a wire bundle assembly; and a fire shield, disposed between the shelland the movement unit, configured to separate the input contact terminaland the output contact terminal from the shell.

In some embodiments, the fire shield is formed of a high temperatureresistant material.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention are described withreference to the drawings. These drawings serve to explain theembodiments and their operating principle, and only illustratestructures that are necessary to the understanding of the principles ofthe invention. These drawings are not necessarily to scale. In thedrawings, like features are designated by like reference symbols.

FIG. 1 is an exploded view of an LCDI device according to an embodimentof the present invention.

FIGS. 2 a-2 d illustrate the structures and engagement of the movementunit and the wire bundle assembly of the LCDI device of the embodiment.

FIG. 3 is an illustration of the structures of the movement assembly andthe shell base of the LCDI device.

FIG. 4 is another illustration of the structures of the movementassembly and the shell base of the LCDI device.

FIG. 5 illustrates an overall structure of the LCDI device.

FIG. 6 illustrates the upper cover of the shell of the LCDI device.

FIG. 7 illustrates the cooperation and engagement of the upper cover andthe base of the shell of the LCDI device.

FIG. 8 is a perspective view showing the movement assembly of the LCDIdevice.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Preferred embodiments of the present invention are described below withreference to the drawings. These drawings and descriptions explainembodiments of the invention but do not limit the invention. Thedescribed embodiments are not all possible embodiments of the presentinvention. Other embodiments are possible without departing from thespirit and scope of the invention, and the structure and/or logic of theillustrated embodiments may be modified. Thus, it is intended that thescope of the invention is defined by the appended claims.

In the descriptions below, terms such as “including” are intended to beopen-ended and mean “including without limitation”, and can includeother contents. “Based on” means “at least partly based on.” “Anembodiment” means “at least one embodiment.” “Another embodiment” means“at least another embodiment,” etc.

Embodiments of the present invention address the following technicalproblems: To reduce the complexity of the assembly of the LCDI device,and to improve production efficiency.

To solve the above problems, embodiments of the present inventionprovide an LCDI device, which includes a shell, a movement unit, and awire bundle assembly. The shell includes a base and an upper coverconnected to each other. The movement unit is disposed in the base, andincludes at least one connecting conductor. A first end of the wirebundle assembly is disposed in the upper cover and includes at least oneshield detection line, where the shield detection line is electricallycoupled to the connecting conductor. The shield detection line includesa connecting terminal at the first end of the wire bundle assembly whichis configured to received and retain the connecting conductor insertedtherein.

FIG. 1 (exploded view) illustrates an overall structure of the LCDIdevice according to an embodiment of the present invention. The LCDIdevice includes a shell (which includes an upper cover 1, a base 3, anda rear cover 6), a movement unit 2, a wire bundle assembly 5, and a fireshield 4. The movement unit 2 is disposed in the base 3, and the fireshield 4 is disposed between the movement unit 2 and the base 3. Themovement unit 2 is electrically and mechanically coupled to the wirebundle assembly 5. A part of the wire bundle assembly 5 is disposed inthe rear cover 6 (between the rear cover 6 and the upper cover 1). Theupper cover 1 is coupled to the base 3 and rear cover 6.

The movement unit 2 includes a light emitting element 22, a waterproofcap 23, an inner cover 24, a reset button 25 and a movement assembly 21.The light emitting element 22, waterproof cap 23, inner cover 24 andreset button 25 are disposed on the movement assembly 21.

As shown in FIGS. 2 a-2 d , the movement assembly 21 includes a pair ofconnecting conductors 211, and one end of the wire bundle assembly 5includes a pair of shield detection lines, where the pair of shielddetection lines are respectively coupled to the pair of connectingconductors 211. More specifically, each connecting conductor 211includes a conductor plate 2113, which includes a positioning hole 2111near the end and at least one position limiting structure 2112 at oneside. In the illustrated embodiment, two position limiting structures2112 (protrusions) are provided, respectively located on the two sidesof the conductor plate 2113.

Further, each shield detection line of the wire bundle assembly 5 isprovided with a connecting terminal 51. The connecting terminal 51 has abump 511 on its inner side. As shown in FIGS. 2 a-2 d , in thisembodiment, the bump 511 is a metal spring plate. When each connectingconductor 211 is inserted into the corresponding connecting terminal 51,the bump 511 falls into the positioning hole 2111. Meanwhile, theconnecting terminal 51 further includes a pair of resilient tabs 512,which push the conductor plate 2113 toward the bump 511 to retain theconductor plate 2113 in the connecting terminal 51. The positionlimiting structures 2112 limit the longitudinal position of theconductor plate 2113 within the connecting terminal 51. This way, theconductor plate 2113 is electrically coupled to the corresponding shielddetection line.

In this embodiment, by using the connecting terminals, the shielddetection lines can be quickly connected to the corresponding conductorplates of the movement assembly by directly inserting the conductorplates into the connecting terminals. This achieves fast assembly andsecure connection.

As shown in FIGS. 3-5 , the movement assembly 21 has at least one firstfastener member 212 located on a first sidewall (not shown) of themovement assembly, and at least one second fastener member 213 locatedon a second sidewall (not shown) opposite the first sidewall. In theillustrated embodiment, two second fastener members 213 are provided.

Correspondingly, the base 3 has at least one first fastener member 31located on a first sidewall (not shown) of the base, and at least onesecond fastener member 32 located on a second sidewall (not shown)opposite the first sidewall. The first and second sidewalls are joinedto the bottom plate of the base 3. In the illustrated embodiment, twosecond fastener members 32 are provided.

When assembling the movement unit 2 in the base 3, each first fastenermember 212 of the movement unit 2 cooperates with a corresponding firstfastener member 31 of the base 3, and each second fastener member 213 ofthe movement unit 2 cooperates with a corresponding second fastenermember 32 of the base 3.

In this embodiment, preferably, the first fastener member 31 of the base3 is a hook, and the amount of its elastic deformation is larger thanthat of the first fastener member 212 (a hook retainer) of the movementunit 2; the second fastener member 213 of the movement unit 2 is a hook,and the amount of its elastic deformation is larger than that of thesecond fastener member 32 (a hook retainer) of the base 3. It should benoted that the structures of the first and second fastener members 212and 213 of the movement unit 2 and the corresponding first and secondfastener members 31 and 32 of the base 3 are not limited to the hooksand hook retainers described above. Rather, any suitable structures maybe used, such as hooks of various shapes, hook retainer of variousshapes, protrusions of various shapes, recesses of various shapes, etc.

The fastener structures described above allow the movement unit 2 to beeasily assembled in the base 3, without the assistance of any tools.This saves time and improves yield and production efficiency.

As shown in FIGS. 3, 4, 6 and 7 , the upper cover 1 has at least onethird fastener member 11 located on a first sidewall (not shown), and atleast one fourth fastener member (not shown) located on a secondsidewall opposite the first sidewall. The base 3 has at least one thirdfastener member 33 located on a third sidewall (not shown), and at leastone fourth fastener member 34 located on a fourth sidewall (not shown)opposite the third sidewall. The third and fourth sidewalls are adjacentto the first sidewall and joined to the bottom plate of the base 3.

In this embodiment, preferably, two third fastener members 33 areprovided on the third sidewall of the base 3 and two fourth fastenermembers 34 are provided on the fourth sidewall of the base 3. The twothird fastener members 33 of the base 3 respectively correspond to thetwo third fastener members 11 of the upper cover 1, and the two fourthfastener members 34 of the base 3 respectively correspond to the twofourth fastener members of the upper cover 1. It should be noted thatthe structures of the third and fourth fastener members of the uppercover 1 and the corresponding third and fourth fastener members of thebase 3 may gave any suitable structures, such as hooks of variousshapes, hook retainer of various shapes, protrusions of various shapes,recesses of various shapes, etc.

When affixing the upper cover 1 to the base 3, each third fastenermember 11 of the upper cover 1 cooperates with the corresponding thirdfastener member 33 of the base 3, and each fourth fastener member of theupper cover 1 cooperates with the corresponding fourth fastener member34 of the base 3.

The fastener structures described above allow the upper cover 1 to bedirectly affixed to the base 3 during assembly, without the assistanceof any tools or screws. This saves time and improves yield andproduction efficiency.

Further, as shown in FIG. 1 , the fire shield 4 is disposed between themovement unit 2 and the shell to completely cover the movement unit 2with the fire shield 4 so as to separate the pair of input contactterminals 214 and output contact terminals 215 of the movement assembly21 (shown in FIG. 8 ) from the shell. For example, the fire shield 4 mayseparate the contact terminals 214 and 215 from any one or more of theupper cover 1, the base 3 and the rear cover 6. This prevents hightemperature arcs, which may be generated by the contact terminals 214and 215 during disconnection, from melting the shell. The fire shield 4may be formed of a suitable high-temperature resistant material such asceramic, engineering plastic, asbestos, epoxy, metal, polyphenylenesulfide (PPS), etc. Compared to conventional LCDI devices which do notuse an internal fire shield or uses a fire shield that only partiallycovers the movement unit, the LCDI device described in the instantapplication can withstand extreme conditions; even when the internaltemperature is high, the device can still withstand higher temperature,and prevent fire hazard.

In summary, the LCDI device according to embodiments of the presentinvention can be assembled without tools, which enhances the ease ofassembling and increases production efficiency. The device can alsoimprove safety of the device and is more user friendly.

While the present invention is described above using specific examples,these examples are only illustrative and do not limit the scope of theinvention. It will be apparent to those skilled in the art that variousmodifications, additions and deletions can be made to the LCDI device ofthe present invention without departing from the spirit or scope of theinvention.

What is claimed is:
 1. A leakage current detection interrupters (LCDI)device, comprising: a shell, including a base and an upper coverconnected to each other; a movement unit, disposed in the base andincluding at least one connecting conductor; and a wire bundle assembly,having a first end disposed in the upper cover, the first end of thewire bundle assembly including at least one shield detection line,wherein the shield detection line is electrically coupled to theconnecting conductor; wherein the shield detection line includes aconnecting terminal at the first end of the wire bundle assembly,wherein the connecting terminal is configured to receive and retain theconnecting conductor inserted therein; wherein the movement unit furtherincludes at least one first fastener member located on a first sidewallof the movement unit, and at least one second fastener member located ona second sidewall of the movement unit opposite the first sidewall;wherein the base has at least one first fastener member corresponding tothe at least one first fastener member of the movement unit, and atleast one second fastener member corresponding to the at least onesecond fastener member of the movement unit; and wherein each firstfastener member of the movement unit is configured to cooperate with acorresponding first fastener member of the base, and each secondfastener member of the movement unit is configured to cooperate with acorresponding second fastener member of the base, to assemble themovement unit in the base.
 2. The LCDI device of claim 1, wherein theconnecting conductor includes: a conductor plate, the conductor platedefining a positioning hole; and a position limiting structure disposedon one side of the conductor plate.
 3. The LCDI device of claim 2,wherein the connecting terminal includes a bump on an inner side,wherein the bump is configured to fall into the positioning hole of theconductor plate when the conductor plate is inserted into the connectingterminal, and wherein the position limiting structure is configured tolimit a longitudinal position of the conductor plate inserted into theconnecting terminal, whereby the conductor plate and is electricallycoupled to the shield detection line.
 4. The LCDI device of claim 1,wherein the shell further includes a rear cover configured to beconnected to a part of the upper cover, wherein the first end of thewire bundle assembly is disposed between the rear cover and the uppercover.
 5. The LCDI device of claim 1, wherein the movement unit furtherincludes at least one input contact terminal and at least onecorresponding output contact terminal; the LCDI device furthercomprising a fire shield, disposed between the shell and the movementunit, configured to separate the input contact terminal and the outputcontact terminal from the shell.
 6. The LCDI device of claim 5, whereinthe fire shield is formed of a high temperature resistant material.
 7. Aleakage current detection interrupters (LCDI) device, comprising: ashell, including a base and an upper cover connected to each other; amovement unit, disposed in the base and including at least oneconnecting conductor; and a wire bundle assembly, having a first enddisposed in the upper cover, the first end of the wire bundle assemblyincluding at least one shield detection line, wherein the shielddetection line is electrically coupled to the connecting conductor;wherein the shield detection line includes a connecting terminal at thefirst end of the wire bundle assembly, wherein the connecting terminalis configured to receive and retain the connecting conductor insertedtherein; wherein the upper cover includes at least one third fastenermember located on a first sidewall of the upper cover, and at least onefourth fastener member located on a second sidewall of the upper coveropposite the first sidewall; wherein the base has at least one thirdfastener member corresponding to the at least one third fastener memberof the upper cover, and at least one fourth fastener membercorresponding to the at least one fourth fastener member of the uppercover; and wherein each third fastener member of the upper cover isconfigured to cooperate with a corresponding third fastener member ofthe base, and each fourth fastener member of the upper cover isconfigured to cooperate with a corresponding fourth fastener member ofthe base, to assemble the upper cover to the base.
 8. The LCDI device ofclaim 7, wherein the shell further includes a rear cover configured tobe connected to a part of the upper cover, wherein the first end of thewire bundle assembly is disposed between the rear cover and the uppercover.
 9. The LCDI device of claim 7, wherein the connecting conductorincludes: a conductor plate, the conductor plate defining a positioninghole; and a position limiting structure disposed on one side of theconductor plate.
 10. The LCDI device of claim 9, wherein the connectingterminal includes a bump on an inner side, wherein the bump isconfigured to fall into the positioning hole of the conductor plate whenthe conductor plate is inserted into the connecting terminal, andwherein the position limiting structure is configured to limit alongitudinal position of the conductor plate inserted into theconnecting terminal, whereby the conductor plate and is electricallycoupled to the shield detection line.
 11. The LCDI device of claim 7,wherein the movement unit further includes at least one input contactterminal and at least one corresponding output contact terminal; theLCDI device further comprising a fire shield, disposed between the shelland the movement unit, configured to separate the input contact terminaland the output contact terminal from the shell.
 12. The LCDI device ofclaim 11, wherein the fire shield is formed of a high temperatureresistant material.